Real Engineering Cases

Practical copper busbar solutions for BESS,EV battery packs and power distribution systems.

Product

Flexible Insulated Copper Busbar

Color-coded PVC-insulated copper busbars with precision stamping and bending — reliable high-current distribution for industrial electrical cabinets, circuit breakers, and power transmission systems.

Rated Current

Up to 630A

Material

C11000 Copper

Insulation

PVC Coated

Application

Industrial

Challenge

Industrial power distribution systems require safe, reliable connections between circuit breakers, switchgear, and busbar chambers. Traditional wiring is bulky, difficult to organize, and prone to phase identification errors. Compact cabinet spaces demand precise, color-coded solutions that handle high currents while maintaining electrical safety and easy maintenance.

Solution

Our PVC-coated flexible copper busbars are precision stamped and bent from C11000 copper, with color-coded insulation for instant phase identification. Available in ratings from 100A to 630A, with tight tolerance control and custom OEM/ODM shapes to fit your exact cabinet layout.

C11000 copper with 100A-630A current ratings
Color-coded PVC insulation (red/yellow/green/blue)
Precision stamping & bending, ±0.1mm tolerance
Custom OEM/ODM shapes for any cabinet layout

Multiple Sizes Flexible Copper Busbar Collection

Why Choose Us

Key Advantages

Color-Coded Phase ID

Red/yellow/green/blue insulation for instant L1/L2/L3/N phase recognition, reducing wiring errors and maintenance time.

High Current Capacity

C11000 pure copper with ratings from 100A to 630A, suitable for industrial power distribution and circuit breaker connections.

Precision Stamping & Bending

±0.1mm tolerance ensures exact fit in tight cabinet spaces, no on-site modification needed for fast installation.

PVC Insulation Safety

Full-length PVC coating provides reliable electrical insulation, preventing short circuits and improving operator safety.

FAQ

Frequently Asked Questions

What are the color codes used for the busbars?

Red, yellow, green, and blue are standard color codes for three-phase AC systems: typically red for L1, yellow for L2, green for L3, and blue for neutral (N). Custom colors are available upon request to match your specific project requirements.

What current ratings are available?

Our flexible copper busbars are available in rated currents of 100A, 125A, 225A, 250A, and 630A. Custom current ratings can be designed based on your specific application requirements and cabinet dimensions.

What material are these busbars made of?

They are manufactured from C11000 copper (also known as electrolytic tough pitch copper), which offers excellent electrical conductivity of 100% IACS and is the industry standard material for power distribution applications.

What applications are these busbars used for?

These busbars are designed for electric power transmission, indoor and industrial applications, including connections inside electrical cabinets, circuit breaker connections, switchgear assemblies, and power distribution units.

What manufacturing processes are used?

The busbars are produced using stamping and bending processes with punching machines and bending machines. This ensures consistent hole positioning, accurate bend angles, and tight tolerance control of 0.05 to +/-0.1mm.

Can you customize the shape and dimensions?

Yes. We offer full OEM and ODM customization services for stamping, bending, and machining. Send us your drawing or specifications and we can produce busbars tailored to your exact cabinet layout and connection requirements.

What surface treatments are available?

Available surface treatments include anodization, powder coating, electroplating (tin or nickel), and oxide treatment. Terminal areas are typically plated for improved conductivity and corrosion resistance, while the body is PVC-coated for insulation.

What certifications do you have?

Our manufacturing facility is ISO9001 certified. Each order undergoes 100% factory quality inspection, and we can provide test reports and certification documentation as required for your project. Minimum order quantity is 50 pieces.

Have a similar project that needs custom busbars?

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